3D Print Geometry Compensation for Acute Angle Distortion
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Solution Overview
Problem
Additive manufacturing processes often result in distortions during the printing of components with acute angles, leading to final models that do not accurately represent the original design due to geometric inaccuracies.
Innovation Solution
A method involving geometric compensation, where the original model is modified to create a compensated model by removing portions at identified acute angles, allowing for the printing of components that more closely resemble the original design by minimizing distortions caused by the printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used to print components with acute angles, then the manufacturing capability and versatility are improved, but the geometric precision and accuracy at acute angles deteriorate due to printer distortions
Solution Approach 1:
The patent applies preliminary action by modifying the digital model before printing to anticipate and compensate for printer distortions. The system identifies acute angles in the original model and removes or rounds portions at these angles in the compensated model, so that when the printer applies its characteristic distortions, the final printed component achieves the desired acute angle geometry.
Solution Approach 2:
The patent implements preliminary anti-action by introducing geometric compensations that counteract the expected harmful effects of printer distortions. The compensation process removes material at acute angles in the digital model, creating an opposite effect that neutralizes the printer's tendency to distort these features, thereby preserving geometric accuracy in the final component.
2Manufacturing precision
If geometric compensation is applied by removing portions at acute angles, then the manufacturing precision is improved, but the loss of substance increases
Solution Approach 1:
The patent applies the taking out principle by selectively removing only the specific portions of material at acute angles that are necessary to compensate for printer distortions. The compensation process identifies and removes only the minimal required material at problematic geometric features, rather than removing excessive material, thereby minimizing the loss of substance while achieving the desired geometric precision.
3Manufacturing precision
If the original model is modified to create a compensated model, then the manufacturing precision is improved, but the device complexity increases due to additional processing steps
Solution Approach 1:
The patent applies self-service by implementing an automated compensation process that identifies acute angles and performs geometric modifications without requiring manual intervention. The system automatically analyzes the original model, identifies problematic features, calculates appropriate compensations, and generates the compensated model, thereby minimizing the increase in device complexity while achieving improved manufacturing precision.
Data Source
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AI summary
A method of printing a component comprising: receiving an original model of the component at a printer, identifying an acute angle in a geometry of the original model; compensating the geometry of the original model at the printer to create a compensated model (154), wherein the compensating includes removing a portion (156) of the original model at the identified acute angle (164); and printing with the printer, the component based upon the compensated model (154).